Bone fusion device

ABSTRACT

A bone fusion device includes a first anchor for insertion into a hole formed in a first phalange, and a second anchor for insertion into a hole formed in a second phalange. A rod includes a handle and a distal end, with the distal end being associated with each of the first anchor and the second anchor. The rod includes a breakaway portion between the handle and the distal end allowing the handle to be manually separated from the distal end.

CLAIM OF PRIORITY

This application is a continuation of U.S. patent application Ser. No. 13/935,107, filed on Jul. 3, 2013, the benefit of priority of which is claimed hereby, and which is incorporated by reference herein in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to bone fusion devices, and, more particularly, to bone fusion devices for fusing phalanges together.

2. Description of the Related Art

Digital deformities of the fingers and toes are some of the most common conditions encountered by orthopedists and podiatrists. Patients with digital deformities often experience significant pain from structural abnormalities. Some of these abnormalities are acquired, caused by traumatic injuries, neuromuscular pathologies, systemic diseases, or mechanical problems secondary to extrinsic pressures. The deformities are popularly known as either mallet finger, jersey finger, coach's finger, hammertoe, as well as a host of others indicative of several different pathologies.

Hammertoe deformity, the most common deformity of the lesser toes, is a flexion deformity of the proximal interphalangeal (PIP) joint of the toe, with hyperextension of the metatarsophalangeal (MTP) and distal interphalangeal (DIP) joints. Progressive PIP joint flexion deformity typically leads to compensatory hyperextension of the MTP and DIP joints. This makes the PIP joint prominent dorsally. Pain occurs due to rubbing of the prominence against the patient's shoe. The deformity is flexible at first but usually becomes fixed over time. When the deformity is flexible, various procedures can be utilized that involve manipulation of the involved tendons (such as orthotics). However, when the deformity is fixed, PIP fusion or joint replacement is often required.

In order to prevent recurrence of the deformity and ensure the success of the surgical procedure, a PIP joint arthrodesis is typically performed. The “end-to-end” or “peg-in-hole” techniques are the most commonly used procedures. The PIP joint is aligned with the rest of the toe in a corrected anatomical position and maintained in place by the use of a Kirschner wire (K-wire) of a selected, diameter which is driven through the joint.

Another type of PIP joint fusion technique utilizes a fusion pin rather than a K-wire driven through the PIP joint. Referring to U.S. Pat. No. 7,041,106 (Carver et al.), which is assigned to the assignee of the present invention, an interphalangeal fusion pin may be used at a PIP joint of a human foot. The fusion pin may have an anatomically correct angle for the PIP joint (FIG. 4 of the '106 patent; e.g., 172.5°), and may be formed from a bioresorbable material.

SUMMARY OF THE INVENTION

The present invention provides a bone fusion device with anchors which are placed into respective holes formed in adjacent bones. A handle may be grasped by hand or with a tool. The handle is attached at a distal end either directly with one of the anchors, or indirectly to one or both anchors through a pin. The handle has a breakaway portion at the distal end which allows the handle to be manually separated from the attached anchor or pin.

The invention in one form is directed to a bone fusion device, including a first anchor for insertion into a hole formed in a first phalange, and a second anchor for insertion into a hole formed in a second phalange. A rod includes a handle and a distal end, with the distal end being associated with each of the first anchor and the second anchor. The rod includes a breakaway portion between the handle and the distal end allowing the handle to be manually separated from the distal end.

In one variant, the first anchor and the second anchor are discrete parts. The first anchor includes a first axial bore and the second anchor includes a second axial bore. The distal end of the rod defines a pin including a first end insertable into the first axial bore and a second end insertable into the second axial bore.

In another variant, the first anchor and the second anchor are monolithic, with the distal end of the rod being coupled with the second anchor at the breakaway portion.

The invention in another form is directed to a bone fusion device including at least one anchor for insertion into a hole formed in a bone, and a rod including a handle and a distal end. The distal end is associated with each anchor. The rod includes a breakaway portion between the handle and the distal end allowing the handle to be manually separated from the distal end.

The invention in yet another form is directed to a method of fusing adjacent bones together, including the steps of: forming a first hole in an end of a first phalange; inserting a first anchor into the first hole; providing a rod including a handle and a distal end, the distal end being associated with the first anchor; separating the rod at a breakaway portion between the handle and the distal end; forming a second hole in an end of a second phalange; and inserting a second anchor into the second hole.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a perspective view of an embodiment of an anchor forming part of a bone fusion device of the present invention;

FIG. 2 is a side view of the anchor shown in FIG. 1;

FIG. 3 is an end view of the anchor shown in FIGS. 1 and 2;

FIG. 4 is an opposite end view of the anchor shown in FIG. 3;

FIG. 5 is a perspective view of an embodiment of a rod used with the anchor shown in FIGS. 1-4;

FIG. 6 is a side view of the rod shown in FIG. 5;

FIG. 7 is a side sectional view of the anchor shown in FIGS. 1-4, with the distal end of the rod threaded therein;

FIG. 8 is a side view of a pair of anchors inserted within adjacent ends of phalanges, with the distal end of the rod inserted into one of the anchors, prior to detachment of the handle from the distal end of the rod;

FIG. 9 is a side view of the anchor shown in FIG. 8, with the pin formed by the distal end of the rod inserted within each of the anchors;

FIG. 10 is a perspective view of another embodiment of a bone fusion device of the present invention;

FIG. 11 is a side view of the bone fusion device shown in FIG. 10;

FIG. 12 is a distal end view of the bone fusion device shown in FIGS. 10 and 11;

FIG. 13 is a proximal end view of the bone fusion device shown in FIGS. 10-12, taken along line 13-1:3 in FIG. 11;

FIG. 14 is a perspective view of yet another embodiment of a bone fusion device of the present invention;

FIG. 15 is a distal end view of the bone fusion device shown in FIG. 14; and

FIG. 16 is a fragmentary, perspective view of still another embodiment of a bone fusion device of the present invention.

Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrate embodiments of the invention, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings, and more particularly to FIGS. 1-4, there is shown an embodiment of an anchor 10 forming part of a bone fusion device 12 (discussed in more detail below with reference to FIGS. 7-9) of the present invention. In the illustrated embodiment, the bone fusion device is assumed to be used during a surgical procedure for the correction of a hammertoe condition. However, it is to be understood that the bone fusion device of the present invention may be used for fusing other adjacent bones together. Moreover, only a single anchor 10 is shown in FIGS. 1-4 for the purposes of illustration. However, it is to be understood that during a surgical procedure using a bone fusion device of the present invention, a second anchor will likely be used which is substantially identical to anchor 10 shown in FIGS. 1-4. Accordingly, for purposes of discussion, anchor 10 is assumed to be a first anchor used during a surgical procedure, with a substantially identical second anchor 14 (shown in FIGS. 7-9) also being used during the surgical procedure.

First anchor 10 includes a body 16 with a first axial bore 18. Body 16 includes a plurality of anti-rotation features 20 to inhibit rotational movement of first anchor 10 relative to a respective phalange when first anchor 10 is placed within a corresponding hole formed in the phalange. In the illustrated embodiment, anti-rotation features 20 are in the form of a plurality of radially movable tabs, each with an ear 22 which extends radially outward from the outer circumference of body 16 when in an at-rest position. Each ear 22 has a ramped surface 24 facing the pointed, closed end 26 which allows the ear 22 to be biased radially inwardly when first anchor 10 is inserted into a hole in a bone. In the embodiment shown in FIGS. 1-4, first anchor 10 includes four ears 22 positioned approximately 90° apart about the periphery of body 16, staggered in a fore-to-aft manner between adjacent ears 22. However, other configurations are also possible.

Referring now to FIGS. 5 and 6, there is shown an embodiment of a rod 30 which forms a part of the bone fusion device 12 of the present invention. Rod 30 generally includes a handle 32 and a distal end 34. Distal end 34 defines a pin which is associated with each of first anchor 10 and second anchor 14 (FIG. 7). More particularly, the pin defined by distal end 34 includes a first end 36 which is insertable into the first axial bore 18 of first anchor 10, and a second end 38 which is insertable into a second axial bore 40 of second anchor 14.

Rod 30 also includes a breakaway portion 42 positioned between handle 32 and distal end/pin 34. Breakaway portion 42 allows handle 32 to be manually separated from distal end/pin 34. As may be seen in each of FIGS. 5 and 6, breakaway portion 42 has a cross-section which is reduced in thickness relative to handle 32. In the illustrated embodiment, breakaway portion 42 has a cross section which is substantially circular, but may be differently shaped depending upon the application. For example, breakaway portion 42 can have a cross-section which is hexagonal, elliptical, triangular, etc.

Referring now to FIG. 7, bone fusion device 12 is shown in an assembled state. When in an assembled state, first end 36 of pin 34 is threaded into first anchor 10, and second end 38 of pin 34 is press-fitted into and snap-locked within second anchor 14. When pin 34 is installed within each anchor 10 and 14, tabs 20 are biased radially outward such that ears 22 dig into the sidewall of the hole formed in the bone, thereby preventing rotation of anchors 10 and 14 within the holes. First anchor 10 and second anchor 14 preferably abut each other in an end-to-end manner, thereby providing sufficient rigidity for fusion of the adjacent phalanges.

In another embodiment (not shown) similar to FIG. 7, first anchor 10 can be eliminated and first end 36 can be screwed directly into a hole formed in a bone. Second end 38 can still be press-fitted into the second axial bore 40 formed in second anchor 14. The orientation of first end 36 installed in one bone and second anchor 14 installed in an adjacent bone can be either direction, proximal or distal.

FIGS. 8 and 9 illustrate a surgical procedure utilizing bone fusion device 12. A hole 44 is formed in the distal end of a proximal phalange 46 by drilling or other means. First anchor 10 has a diameter which is slightly larger than the inside diameter of hole 44 so as to form an interference fit therewith. First anchor 10 is inserted into the hole 44 using any suitable placement technique, such as manually or with a tool. The first end 36 of distal end/pin 34 is then threaded into first anchor 10 until seated adjacent closed end 26. This may be accomplished by either manually grasping handle 32, or attaching handle 32 to a tool or driver. When first end 38 of distal end/pin 34 is in place within first axial bore 18, the tabs 20 prevent rotation of first anchor 10 within hole 44.

With another option, first anchor 10 which is shown in phantom lines in FIGS. 8 and 9 can be eliminated, and first end 36 can be screwed directly into a hole formed in the proximal phalange 46. The inside diameter of the hole formed in the proximal phalange 46 would be sized to allow the external threads of first end 36 to self-tap into the hole.

Rod 30 is then manually bent and/or twisted to separate handle 32 from distal end/pin 34 at breakaway portion 4. After separation of handle 32 from distal end 34, distal end. 34 then becomes the pin 34 that is received within each axial bore of first anchor 10 and second anchor 14. A hole 48 is also formed in the proximal end of distal phalange 50. Second anchor 14 is inserted into the hole 48 using any suitable placement technique, as noted above. The formation of hole 48 within distal phalange 50 and placement of second anchor 14 within hole 48 can occur either before or after placement of distal end/pin 34 within first anchor 10, depending upon the preferences of the surgeon. Distal phalange 50 is distended a sufficient amount allowing second anchor 14 to be positioned longitudinally adjacent to second end 40 of pin 34. Second anchor 14 is slid over second end 40 of pin 34 until second anchor 40 is seated against first anchor 10 (snap fit). With bone fusion device 12 in an assembled state as shown in FIG. 9, fusion between proximal phalange 46 and distal phalange 50 can occur. Alternatively, the orientation of first anchor 10 and second anchor 14 can be reversed, such that second anchor 14 is located in the proximal phalange and first anchor 10 is located in the distal phalange.

Referring now to FIGS. 10-13, there is shown another embodiment of a bone fusion device 60 of the present invention. Bone fusion device 60 is similar to bone fusion device 12, in that it includes a first anchor 62 and a second anchor 64 which are received within respective holes formed in adjacent bones. However, bone fusion device 60 differs from bone fusion device 12 in that first anchor 62 and second anchor 64 are monolithically formed together as a single piece. First anchor 62 and second anchor 64 each include a plurality of anti-rotation features which inhibit rotational movement relative to a respective phalange when placed within a respective hole of the phalange. In the embodiment shown in FIGS. 10-13, each anchor 62 and 64 includes four notches 66 which are formed in an exterior surface thereof at approximate 90° angular intervals. Notches 66 dig into the bone to prevent rotation when anchors 62 and 64 are placed within the respective holes.

First anchor 62 includes a tip 68 which extends axially in a direction opposite from rod 70. Tip 68 preferably has an outside diameter which is slightly larger than a K-wire used to form an initial hole in the end of a phalange, and thereby forms an interference fit with the hole formed by the K-wire.

Rod 70 has a handle 72 with a distal end 74 which is attached to a proximal end of second anchor 64. A breakaway portion 76 located at the distal end 74 allows handle 72 to be manually separated from second anchor 64. Breakaway portion 76 has a circular cross section in the embodiment shown in FIGS. 10-13 (see FIG. 13), but can have a different shaped cross-section for other applications.

Referring now to FIGS. 14-15, there is shown yet another embodiment of a bone fusion device 80 of the present invention. Bone fusion device 80 is similar to bone fusion device 60 shown in FIGS. 10-13. However, bone fusion device 80 differs from bone fusion device 60 in that first anchor 82 and second anchor 84 each include only two notches 86 which are formed in an exterior surface thereof at approximate 180° angular intervals.

Referring now to FIG. 16, there is shown yet another embodiment of a bone fusion device 90 of the present invention. Bone fusion device 90 is similar to bone fusion device 80 shown in FIGS. 14-15, in that first anchor 92 and second anchor 94 each include two notches 96 which are formed in an exterior surface thereof at approximate 180° angular intervals. However, the integral first anchor 92 and second anchor 94 each have an exterior surface with a pair of parallel, generally planar walls 98 which further assist in preventing rotation of first anchor 92 and second anchor 94 when installed within respective holes in adjacent bones.

While this invention has been described with respect to at least one embodiment, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims. 

What is claimed is:
 1. A bone fusion device, comprising: a first anchor insertable into a bore created in a first phalange; and a second anchor coupled to the first anchor, the second anchor insertable into a bore created in a second phalange, the first anchor and the second anchor enabling fusion of the first and second phalanges, and a rod coupled to the second anchor, the rod comprising: a handle terminating at a proximal end of the rod; and a breakaway portion coupling the handle to the second anchor, the rod separable from the second anchor at the breakaway portion, at least a portion of the breakaway portion insertable into the bore in the second phalange after separation of the handle from the second anchor.
 2. The bone fusion device of claim 1, the first anchor further comprising: a tip extending from the first anchor, away from the second anchor, the tip insertable into a second bore of the first phalange formed by a k-wire, the tip engaging the second bore in an interference fit arrangement.
 3. The bone fusion device of claim 1, wherein the breakaway portion has a cross section that is smaller than a handle cross section.
 4. The bone fusion device of claim 1, wherein the handle is manually separable from the second anchor.
 5. The bone fusion device of claim 1, wherein said handle is separable from the second anchor by one or more of bending and twisting the rod and by breaking the rod at the breakaway portion.
 6. The bone fusion device of claim 1, wherein the first anchor and the second anchor each include at least one anti-rotation feature configured to reduce rotational movement relative to a respective phalange when placed within the bore of one of the first and second the phalanges, respectively.
 7. The bone fusion device of claim 1, wherein at least one of the first anchor and the second anchor includes an anti-rotation notch extending axially along an outer surface of one of the first anchor and the second anchor, the anti-rotation notch engageable with a respective first bore or second bore to prevent rotation of one of the first anchor and the second anchor relative to the first bore and the second bore, respectively.
 8. The bone fusion device of claim 1, wherein the first anchor and the second anchor include a first external wall that is generally planar and a second external wall parallel to and opposite the first external wall and is generally planar, the first wall and the second wall configured to engage the bore of the first phalange and the bore of the second phalange to prevent rotation of the first anchor and second anchor relative to the first phalange and second phalange, respectively.
 9. The bone fusion device of claim 8, wherein the first anchor and the second anchor include an anti-rotation notch extending axially along an outer surface of the first anchor and the second anchor between the first wall and the second wall, the anti-rotation notch configured to engage the bore of the first phalange and the bore of the second phalange to prevent rotation of the first anchor and the second anchor relative to the first phalange and the second phalange, respectively.
 10. The bone fusion device of claim 9, wherein the first anchor and the second anchor include a second anti-rotation notch extending axially along an outer surface of the first anchor and the second anchor between the first wall and the second wall and opposite the antirotation notch.
 11. A bone fusion device, comprising: a first anchor extending distally and securable within a bore in a first phalange; and a second anchor coupled to the first anchor and extending proximally from the first anchor, the second anchor insertable into a bore in a second phalange, the first anchor and the second anchor enabling fusion of the first and second phalanges; a handle extending proximally from the second anchor and terminating at a proximal end; and a breakaway portion seperably coupling the handle to the second anchor, the handle manually separable from the second anchor at the breakaway portion, at least a portion of the breakaway portion securable in an interference fit arrangement within the bore in the second phalange after separation of the handle from the second anchor.
 12. The bone fusion device of claim 11, the first anchor further comprising: a tip extending from the first anchor, away from the second anchor, the tip insertable into a second bore of the first phalange formed by a k-wire, the tip engaging the second bore in an interference fit arrangement.
 13. The bone fusion device of claim 11, wherein the breakaway portion has a cross section that is smaller than a handle cross section.
 14. The bone fusion device of claim 11, wherein the handle is manually separable from the second anchor.
 15. The bone fusion device of claim 11, wherein said handle is separable from the second anchor by one or more of bending and twisting the handle and by breaking the handle at the breakaway portion.
 16. The bone fusion device of claim 11, wherein the first anchor and the second anchor each include at least one anti-rotation feature configured to reduce rotational movement relative to a respective phalange when placed within the bore of one of the first and second the phalanges, respectively.
 17. The bone fusion device of claim 11, wherein at least one of the first anchor and the second anchor includes an anti-rotation notch extending axially along an outer surface of one of the first anchor and the second anchor, the anti-rotation notch engageable with a respective first bore or second bore to prevent rotation of one of the first anchor and the second anchor relative to the first bore and the second bore, respectively.
 18. The bone fusion device of claim 11, wherein the first anchor and the second anchor include a first external wall that is generally planar and a second external wall parallel to and opposite the first external wall and is generally planar, the first wall and the second wall configured to engage the bore of the first phalange and the bore of the second phalange to prevent rotation of the first anchor and second anchor relative to the first phalange and second phalange, respectively.
 19. The bone fusion device of claim 18, wherein the first anchor and the second anchor include an anti-rotation notch extending axially along an outer surface of the first anchor and the second anchor between the first wall and the second wall, the anti-rotation notch configured to engage the bore of the first phalange and the bore of the second phalange to prevent rotation of the first anchor and the second anchor relative to the first phalange and the second phalange, respectively.
 20. The bone fusion device of claim 19, wherein the first anchor and the second anchor include a second anti-rotation notch extending axially along an outer surface of the first anchor and the second anchor between the first wall and the second wall and opposite the antirotation notch. 